Mechanically-driven, sonic toothbrush system

ABSTRACT

A sonic toothbrush system includes an electric motor, a brush shaft, and a drive assembly. The electric motor includes a drive shaft. When the electric motor is caused to operate, the drive shaft continuously rotates until the motor is caused to stop. The drive assembly is coupled between the drive shaft and the brush shaft. The drive assembly is configured to convert the rotation of the drive shaft into sonic oscillation of a toothbrush head supported on an end of the brush shaft.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. patent applicationSer. No. 13/462,614, filed May 2, 2012, which claims priority pursuantto 35 U.S.C. § 119(e) to U.S. provisional application No. 61/481,357filed 2 May 2011 entitled “Mechanically driven sonic toothbrush system,”which is hereby incorporated herein by reference in its entirety.

TECHNICAL FIELD

The present disclosure relates to oral health products. Morespecifically, the present invention relates to sonic toothbrush systems.

BACKGROUND

The state of the art in sonic toothbrush technology centers around drivesystems that create a desired oscillating toothbrush output motion byusing electro-magnetic drivers and centering return springs to directlycreate oscillating motion. No continuous input rotation or drivers areinvolved in these electro-magnetic systems and such electro-magneticsystems have a relatively high production cost.

There are also currently many toothbrushes that provide oscillatingoutput brush motion from continuously rotating input drivers. Suchmechanically-driven toothbrushes typically have a reduced manufacturingcost as compared to toothbrushes employing electro-magnetic drivers.However, such rotating systems all perform the oscillating function atspeeds well below sonic level. There are no continuously rotating inputdrive systems that operate at sonic speeds.

The information included in this Background section of thespecification, including any references cited herein and any descriptionor discussion thereof, is included for technical reference purposes onlyand is not to be regarded subject matter by which the scope of theinvention as defined in the claims is to be bound.

SUMMARY

One exemplary implementation of a mechanically-driven, sonic toothbrushincludes an electric motor, a brush shaft, and a drive assembly. Theelectric motor may be a continuously rotating input driver (e.g., a DCmotor) that drives a specifically balanced drive assembly with a linkagesystem to change the continuous rotation of the input driver into thedesired oscillating output motion which drives the attached toothbrushhead at a sonic speed(s). The electric motor includes a drive shaft.When the electric motor is actuated, the drive shaft continuouslyrotates until the motor is arrested. The drive assembly is coupledbetween the drive shaft and a brush shaft. The drive assembly isconfigured to convert the rotation of the drive shaft into sonicoscillation of a toothbrush supported on an end of the brush shaft.

In another implementation of the sonic toothbrush system, the driveassembly includes a coupler and an eccentric pin. The coupler has afirst end and a second end. The first end is operably coupled to thebrush shaft and the eccentric pin is rotationally received within thesecond end. The rotation of the drive shaft causes the eccentric pin torotate within the second end. The rotation of the eccentric pin causesthe coupler to oscillate.

In a further exemplary implementation, a sonic toothbrush may have anelectric motor including a drive shaft, a brush shaft, and a driveassembly. When the electric motor is caused to operate, the drive shaftcontinuously rotates until the motor is caused to stop. The driveassembly may be coupled between the drive shaft and the brush shaft andconfigured to convert the rotation of the drive shaft into sonicoscillation of a toothbrush head supported on an end of the brush shaft.

In an additional exemplary implementation, a sonic toothbrush mayprovide oscillating bristle motion. The sonic toothbrush may include acontinuously rotating drive system, a brush shaft, and a linkage betweenthe drive system and the brush shaft that provides oscillating, sonicspeed output motion to the brush shaft with an extremely low level ofmechanical vibration and noise.

In yet another exemplary implementation, a method of designing a sonictoothbrush is disclosed. The sonic toothbrush may have a continuouslyrotating drive system, a brush shaft, and a linkage between the drivesystem and the brush shaft. The method may involve performing a finiteelement analysis on the linkage and then determining a weightdistribution in the linkage based upon the finite element analysis toposition a center of mass of the linkage and impart a balance or aselected imbalance to the linkage. The method may further involveadjusting one or more replaceable weights within the linkage to alterthe center of mass or alter the selected imbalance.

This Summary is provided to introduce a selection of concepts in asimplified form that are further described below in the DetailedDescription. This Summary is not intended to identify key features oressential features of the claimed subject matter, nor is it intended tobe used to limit the scope of the claimed subject matter. A moreextensive presentation of features, details, utilities, and advantagesof the present invention as defined in the claims is provided in thefollowing written description of various embodiments of the inventionand illustrated in the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a brush end isometric view of an exemplary implementation of amechanically-driven, sonic toothbrush system.

FIG. 2 is a side view of the mechanically-driven, sonic toothbrushsystem of FIG. 1 with the housing removed.

FIG. 3 is a bottom isometric view of the mechanically-driven, sonictoothbrush system of FIG. 1 with the housing removed.

FIG. 4 is a top isometric view of the drive bracket of themechanically-driven, sonic toothbrush system of FIG. 1 and thecomponents supported thereon.

FIG. 5 is a bottom isometric view of the drive bracket of themechanically-driven, sonic toothbrush system of FIG. 1 and thecomponents supported thereon.

FIG. 6 is a top isometric view of the mechanically-driven, sonictoothbrush system of FIG. 1 drive bracket and the components supportedthereon.

FIG. 7 is a partially exploded view of the drive bracket of themechanically-driven, sonic toothbrush system of FIG. 1 and thecomponents supported thereon.

FIG. 8 is a front isometric view of the brush shaft, drive assembly, andmotor of the mechanically-driven, sonic toothbrush system of FIG. 1mechanically coupled together for operation.

FIG. 9 is the same view as FIG. 8 with the motor, rear bearing, andbushing removed.

FIG. 10 is an exploded isometric view of the drive assembly and brushshaft of the mechanically-driven, sonic toothbrush system of FIG. 1.

FIG. 11 is an exploded, front isometric view of the main components ofthe drive assembly of the mechanically-driven, sonic toothbrush systemof FIG. 1.

FIG. 12 is an exploded, side isometric view of the main components ofthe drive assembly of the mechanically-driven, sonic toothbrush systemof FIG. 1.

FIG. 13 is an exploded rear isometric view of the main components of thedrive assembly of the mechanically-driven, sonic toothbrush system ofFIG. 1.

FIG. 14 is generally the same isometric view of the motor, driveassembly, and brush shaft as depicted in FIG. 8, further depicting across section extending through the axis of the motor drive shaft andthe eccentric pin.

FIG. 15 is generally the same isometric view of the motor, driveassembly and brush shaft as depicted in FIG. 8, further depicting across section extending through the axis of the pivot pin of the rockerarm.

DETAILED DESCRIPTION

Several exemplary embodiments of a mechanically-driven, sonic toothbrushsystem are disclosed herein. The sonic toothbrush system makes use of acontinuously rotating input driver (e.g., a DC or AC motor) thatoperates a balanced linkage system to change the continuous rotation ofthe input driver into a desired oscillating output motion, which drivesthe attached toothbrush head at a sonic speed or speeds.

The mechanically-driven, sonic toothbrush system may have a lowerproduction cost than the current electro-magnetic sonic toothbrushsystems due to the use of DC drive motors for input drive motion and theuse of relatively inexpensive molded plastic components. Themechanically-driven, sonic toothbrush system, due in part to its balanceweights, allows its mechanical drive to provide sonic output motion witha low level of vibration and noise. The weights (i.e., plugs or othercomponents of a selected mass) can be tailored to produce these reducedvibration and noise levels at various output oscillation speeds, fromsub-sonic through sonic. This tailored weight aspect of the mechanicaldrive allows a single basic system design to be used for a wide range ofsub-sonic through sonic brush outputs and models by changing the balancecomponents during brush manufacture.

Thus, the exemplary mechanically-driven, sonic toothbrush systemsdisclosed herein may provide a continuously rotating input drive systemthat provides oscillating, sonic-speed toothbrush output motion with anextremely low level of mechanical vibration and noise. Also, theexemplary mechanically-driven, sonic toothbrush systems disclosed hereinprovide a sonic toothbrush system at a reduced production cost.

The use of “sonic” or “sonic speed” herein refers to the frequency ofoscillation of the brush head of the toothbrush and means that suchfrequency is within the range of sound frequencies (i.e., between 20 Hzand 20,000 Hz). Typically, sonic toothbrushes operate at a range ofbetween 200 and 300 cycles per second. In exemplary implementations ofthe disclosed mechanically-driven, sonic toothbrush system disclosedherein, the motor may operate at between 200 and 300 rotations persecond (i.e., between 12,000 and 18,000 rpm).

An exemplary embodiment of a mechanically-driven, sonic toothbrushsystem 10 disclosed herein is depicted in FIG. 1, which is a brush endisometric view of the system 10. As shown in FIG. 1, the system 10includes a brush end 12, a base end 14 opposite the brush end, a housing16 extending between the ends 12, 14 and forming the surface of thesystem 10, and a generally flat base 18 on which the system 10 may bestood upright on a planar surface, such as a countertop. A brush shaft20 extends out of the housing 16 at the brush end 12 from the systemdrive assembly enclosed by the housing 16 and discussed below. A shaftseal 21 extends about the shaft 20 between the housing 16 and shaft 20at the brush end 12 and is configured to allow the shaft 20 to oscillatewhile preventing the ingress of fluids into the interior of the housing.

The housing 16 may be generally cylindrically shaped to ergonomicallyfit in the hand of a user. The cylindrical shape may taper in thedirection of the brush end 12 approximately one third the length of thehousing 16 from the brush end 12. A control button 22 is supported onthe housing 16 and actuates the system drive assembly between on and offand additionally, in some instances, between a range of speeds. A faceplate 23 is supported on the housing 16 in a region extending about thecontrol button 22. A toothbrush 25 (shown in phantom lines) is mountedon the end of the brush shaft 20. The toothbrush 25 includes a pluralityof bristles 27.

As shown in FIGS. 2 and 3, which are, respectively, a side view and abottom isometric view of the system 10 with the housing 16 removed, thesystem 10 includes an internal support structure formed by a chassis 24extending towards the base end 14 and a drive bracket or chassis 26extending towards the brush end 12. An induction coil 28 is wound arounda bobbin and is located between the interior side of the flat base 18and a base end 14 side of the chassis 24. A rechargeable battery pack 30is electrically coupled to the induction coil 28 and supported in apocket of the chassis 24 on a brush end 12 side of the charger coil 28.

As illustrated in FIGS. 2 and 3, an electric DC motor 32 is supportedoff of the chassis 24 and drive bracket 26 near the overlap of thesestructures. The motor 32 is electrically coupled to the battery pack 30via electrical control circuits 33 of a printed circuit board 34supported off of the chassis 24 and drive bracket 26. The electricalcontrol circuits 33 are actuated via the control button 22 to cause themotor 32 to operate at different states (e.g., on, off, high speed, lowspeed, etc.). In one embodiment, the electrical control circuits 33controlling the motor 32 include one or more trim pots that allowprecise control of frequency and motor speed.

As depicted in FIGS. 4 and 5, which are, respectively, a top isometricview and a bottom isometric view of the drive bracket 26 and thecomponents supported thereon, the system drive assembly 36 is supportedwithin a pocket of the drive bracket 26. The drive assembly 36mechanically couples the output shaft 37 of the motor 32 to the brushshaft 20 to cause the brush shaft 20 to oscillate at sonic speeds whenthe motor 32 causes its output shaft 37 to continuously rotate.

As illustrated in FIGS. 6, 7 and 10, which are, respectively, a topisometric view and first and second partially exploded views of thedrive bracket 26 and the components supported thereon, the drive bracket26 includes a front bearing ring 38 and a rear bearing ring 40. The rearbearing ring 40 may be multi-piece with a bearing bracket 41 forming theupper portion of the bearing ring 40 mounted to the drive bracket 26,which forms the lower portion of the rear bearing ring 40. The frontbearing ring 38 includes a bushing or bearing 42, and the rear bearingring 40 includes a bushing or bearing 44. The bearings 42, 44 may beball or roller type bearings in some embodiments. The bearing 44 of therear bearing ring 40 supports the rear end of the brush shaft 20, andthe bearing ring 42 of the front bearing ring 38 supports the brushshaft 20 near the midpoint of the brush shaft 20.

As can be understood from a comparison of FIGS. 4 and 5 to FIG. 6, anisolator damper 46 extends about the front bearing ring 38 and acts tovibrationally isolate the moving components of the system 10 from thehousing 16 that surrounds the damper 46 and moving components of thesystem 10.

As shown in FIG. 8, which is a front isometric view of the brush shaft20, the drive assembly 36 and the motor 32 are mechanically coupledtogether for operation. The bearings 42, 44 support the shaft 20 and therear end of the shaft 20 is received in a rocker arm 48 forming a frontend of the drive assembly 36. Also, the motor output shaft 37 extendsinto a motor crank arm 50 forming a rear end of the drive assembly 36.The motor crank arm 50 is coupled to the rocker arm 48 via a dog bonecoupler 52. An eccentric pin 53 extends from the motor crank arm 50 andthrough a lower portion of the coupler 52 to be received in a supportbushing 54. The eccentric pin 53 acts as a cam and causes the lowerportion of the coupler 52 to revolve about the axis of the motor shaft37.

As indicated in FIG. 9, which is the same view as FIG. 8, with the motor32, the rear bearing 44, and the bushing 54 removed, the front end ofthe brush shaft 20 is configured to engage with a brush head (notshown). For example, the brush shaft 20 may include a flat region 56 atits front end. The rear end of the brush shaft 20 is configured toengage 48 with the rocker arm 48. For example, the brush shaft 20 mayinclude a flat region 58 at its rear end.

As shown in FIG. 10, which is an exploded isometric view of the driveassembly 36 and the shaft 10, the motor crank arm 50 includes balanceweights 60 that are fixedly received in apertures 61 in the motor crankarm 50, as indicated by dashed lines identified at A and A′. Similarly,the rocker arm 48 includes a balance weight 62 that is fixedly receivedin an aperture 63 in the rocker arm 48, as indicated by the dashed lineidentified at B. The weights 60, 62 may act to counterbalance thecomponents of the drive assembly 36 on which the weights 60, 62 aremounted to reduce noise and vibration in the drive assembly 36.

As illustrated in FIG. 10, a rearward end 53′ of the eccentric pin 53 isfixedly received in the motor crank arm 50, as indicated by the dashedline identified at C. An enlarged diameter eccentric mid portion 53″ ofthe eccentric pin 53 is rotationally received in a bearing 66, which isfixedly received in a lower aperture 65 of the dog bone coupler 52, andthe forward end 53″ of the eccentric pin 53 is rotationally received inthe bushing 54. All of this indicated by the dashed line identified atD. The pivot pin 67 of the rocker arm 48 is pivotally or oscillatinglyreceived in a bearing 68, which is fixedly received in an upper aperture69 of the dog bone coupler 52, as indicated by the dashed lineidentified at E. Finally, as explained above, the brush shaft 20 ispivotally or oscillatingly located within the bearings 42, 44, and therearward end of the shaft 20 is fixedly received in an aperture 70 therocker arm 48, all of this indicated by the dashed line identified at F.

For a discussion of the features of some of the main components of thedrive assembly 36, reference is made to FIGS. 11, 12 and 13. FIG. 11 isan exploded, front isometric view of the main components of the driveassembly 36. FIG. 12 is an exploded, side isometric view of the maincomponents of the drive assembly 36. FIG. 13 is an exploded, rearisometric view of the main components of the drive assembly 36. Asillustrated in FIGS. 11, 12 and 13, the motor crank arm 50 includes acentral axis aperture 71, a dual lobe portion 72, a cylindrical portion74, a conical portion 76, and apertures 61 for receiving the balanceweights 60. The lobe portion 72 has a small lobe 78 and a large lobe 80opposite the central axis aperture 71 from the small lobe 78. The lobes78, 80 each include a weight-receiving aperture 61, generally centeredin the respective lobe 78, 80. The cylindrical portion 74 extendsrearward of the lobe portion 72 and the conical portion 76 extendsforward of the lobe portion 72. The central axis aperture 71 extendsrearward to forward through the motor crank arm 50, starting at the mostrearward face of the cylindrical portion 74 and ending at the mostforward face of the conical portion 76. The central axis aperture 71 isgenerally coaxial with the axis of the cylindrical portion 74.

As depicted in FIGS. 11, 12 and 13, the rocker arm 48 includes a lobedpotion 82, a cylindrical portion 84, and a central axis aperture 70. Thecylindrical portion 84 extends forwardly from the lobed portion 82. Thecentral axis aperture 70 is generally coaxial with the axis of thecylindrical portion 84 and is shaped to fixedly engage the rearward endof the brush shaft 20, for example, the central axis aperture 70 mayhave a flat region 88 to correspond to the flat region 58 of the brushshaft and may further have a slot or keyway 89 to provide an additionalengagement feature). The lobed portion 82 includes a tapered lobe 90 anda rounded lobe 92 opposite the central axis aperture 61 from the taperedlobe 90. The tapered lobe 90 includes a pivot pin 67 extending rearwardfrom the tapered lobe 90 and having an axis generally parallel to theaxis of the central axis aperture 70. The rounded lobe 92 includes aweighted region 94 of increased thickness extending rearward from therounded lobe 92 and having the aperture 63 for receiving the weight 62.

As indicated in FIGS. 11, 12 and 13, the eccentric pin 53 includes arearward end shaft 53′, an enlarged diameter eccentric mid portion 53″,and a forward end shaft 53′″. The rearward end shaft 53′ extendsrearward from the mid portion 53″ and the forward end shaft 53′″ extendsforward from the mid portion 53″. As can be understood from FIGS. 11, 12and 13, the rearward end shaft 53′ and the forward end shaft 53′″ sharea common pivot axis, while the enlarged eccentric mid portion 53″ iseccentric relative to the forward and rearward end shafts 53′, 53′″ andhas a pivot axis offset, but parallel to, the common pivot axis of theforward and rearward end shafts 53′, 53′″.

As shown in FIGS. 11, 12 and 13, the dog bone coupler 52 may have anhourglass shape and include a first rounded end portion 96 (motor crankarm engaging portion) extending into a reduced diameter mid portion 98that extends into a second rounded end portion 100 (rocker arm engagingportion). The first end portion 96 includes an aperture 65 that receivesthe conical portion 76 of the motor crank arm 50 and the eccentric pin53. The second end portion 100 includes an aperture 69 that receives thepivot pin 67 of the rocker arm 48. In one embodiment, the bearing 66used in the dog bone coupler 52 is a model R 133ZZS and the bearing 44utilized for the output brush shaft 20 is a model MR 104ZZ ball bearing.

For a discussion of the operation of the drive assembly 36, whereincontinuous rotation of the motor drive shaft 37 in a single rotationaldirection results in the drive assembly 36 causing the brush shaft 20 tooscillate back and forth, reference is made to FIGS. 8, 14 and 15. FIG.14 is generally the same isometric view of the motor 32, drive assembly36 and brush shaft 20 as depicted in FIG. 8, except a cross section isshown extending through the axis of the motor drive shaft 37 and theeccentric pin 53. FIG. 15 is generally the same isometric view of themotor 32, drive assembly 36, and brush shaft 20 as depicted in FIG. 8,except a cross section extending through the axis of the pivot pin 67 ofthe rocker arm 48 is shown.

As can be understood from FIGS. 8 and 14, once the motor 32 is actuatedby the control button 22 to turn on and run, the motor drive shaft 37,which is fixedly received in the central axis aperture 71 (see FIGS.11-13) of the motor crank arm 50, rotates continuously in a singlerotational direction until the control button 22 is turned to off tostop the motor 32. The rearward end shaft 53′ of the eccentric pin 53 isfixedly received in the central axis aperture 71 of the crank arm 50.The enlarged eccentric mid portion 53″ of the eccentric pin 53 isrotationally received within the bearing 66, which is fixedly receivedin the aperture 65 (see FIGS. 11-13) of the dog bone coupler 52. Theforward end shaft 53″ of the eccentric pin 53 is rotationally receivedin the bushing 54, which is mounted in a fixed position on the drivebracket 26 as shown in FIG. 3. Thus, the rotating motor drive shaft 37causes the motor crank arm 50 and eccentric pin 53 to rotate in the samedirection. Thus, the enlarged eccentric mid portion 53″ and the forwardend shaft 53″ of the eccentric pin 53 rotate in the same direction,respectively, within the bearings 66, 54. The rotation of the enlargedeccentric mid portion 53″ causes the dog bone coupler 52 to move backand forth or, in other words, oscillate.

As can be understood from FIGS. 8, 14 and 15, the pivot pin 67 ispivotally or oscillatingly received in the bearing 68, which is fixedlyreceived in the aperture 69 (see FIGS. 11-13) of the dog bone coupler52. Thus, the back and forth or oscillating displacement of the dog bonecoupler 52 causes the tapered lobe 90 to displace back and forth oroscillate about the axis of the central axis aperture 70 (see FIGS.11-13) of the rocker arm 48. As a result, the rocker arm 48 and thebrush shaft 20 are caused to pivot back and forth or oscillate about thelongitudinal axis of the shaft 20.

As can be understood from the preceding discussion, in some embodiments,the drive assembly 36 used to convert the rotary motor motion intooscillating output brush shaft motion may be a four bar linkage. Therequired balance/imbalance of the various linkage components is relatedto the desired operational speed as well as the desired displacement ofthe oscillating output motion (i.e., different operational speeds andoscillating motion displacements employ different componentbalance/imbalance). In one embodiment, a design software program (e.g.,finite element analysis software) may be used to calculate the desiredcenter of mass locations of the various linkage components to minimizevibration and noise based on the desired design operational speed anddisplacement. The specific size and location of thebalance/counterbalance weights 60, 62 for each component may then befinalized based on the mass of the material used for a component and thespace constraints of the mechanism envelope in order to satisfy thedesired resultant center of mass locations.

In exemplary embodiments, the motor drive shaft 50, dog bone coupler 52,rocker arm 48, and brush shaft 20 may be formed of a polymer material,while the weights 60, 62 may be formed of a metal material such as, forexample, stainless steel, tungsten, etc. In other embodiments, theaforementioned drive assembly components and weights may be formed ofother materials.

All directional references (e.g., proximal, distal, upper, lower,upward, downward, left, right, lateral, longitudinal, front, back, top,bottom, above, below, vertical, horizontal, radial, axial, clockwise,and counterclockwise) are only used for identification purposes to aidthe reader's understanding of the present invention, and do not createlimitations, particularly as to the position, orientation, or use of theinvention. Connection references (e.g., attached, coupled, connected,and joined) are to be construed broadly and may include intermediatemembers between a collection of elements and relative movement betweenelements unless otherwise indicated. As such, connection references donot necessarily infer that two elements are directly connected and infixed relation to each other. The exemplary drawings are for purposes ofillustration only and the dimensions, positions, order and relativesizes reflected in the drawings attached hereto may vary.

The above specification, examples and data provide a completedescription of the structure and use of exemplary embodiments of theinvention as defined in the claims. Although various embodiments of theclaimed invention have been described above with a certain degree ofparticularity, or with reference to one or more individual embodiments,those skilled in the art could make numerous alterations to thedisclosed embodiments without departing from the spirit or scope of theclaimed invention. Other embodiments are therefore contemplated. It isintended that all matter contained in the above description and shown inthe accompanying drawings shall be interpreted as illustrative only ofparticular embodiments and not limiting. Changes in detail or structuremay be made without departing from the basic elements of the inventionas defined in the following claims.

What is claimed is:
 1. A sonic toothbrush comprising a motor including adrive shaft, wherein, when the electric motor is caused to operate, thedrive shaft continuously rotates until the motor is caused to stop; abrush shaft; and a drive assembly coupled between the drive shaft andthe brush shaft and configured to convert the rotation of the driveshaft into sonic oscillation of a toothbrush head supported on an end ofthe brush shaft.